An Aqueous Polymer Dispersion

Abstract

Aqueous dispersions and uses for the same. The aqueous dispersion includes a component (a) of one or more ethylene-vinyl ester copolymers, a component (b) of one or more protective colloids, a component (el) of one or more nonionic surfactants, and a component (d) of one or more dispersants, selected from polycarboxylates. Where an amount of the component (b) and the component (c1) is less than or equal to 3.4 pphm, preferably between 1-3.4 pphm, more preferably between 2-3.1 pphm. Where the weight ratio of an amount of the component (b) to the component (el) is between 1.01-2 and an amount of the component (d) is less than or equal to 1 pphm. The component (b) is polyvinyl alcohol (PVOH).

Claims

1.-10. (canceled)

11. An aqueous polymer dispersion, comprising: a component (a) of one or more ethylene-vinyl ester copolymers; a component (b) of one or more protective colloids; a component (el) of one or more nonionic surfactants; a component (d) of one or more dispersants, selected from polycarboxylates; wherein an amount of the component (b) of one or more protective colloids and the component (c1) of one or more nonionic surfactants is less than or equal to 3.4 pphm, preferably between 1-3.4 pphm, more preferably between 2-3.1 pphm; wherein the weight ratio of an amount of the component (b) of one or more protective colloids to the component (el) of one or more nonionic surfactants is between 1.01-2; wherein an amount of the component (d) of one or more dispersants is less than or equal to 1 pphm; and wherein the component (b) of one or more protective colloids is selected from polyvinyl alcohol (PVOH).

12. The aqueous dispersion of claim 11, wherein the weight ratio of the amount of the component (b) of one or more protective and the component (c1) of one or more nonionic surfactants is between 1.05-1.5.

13. The aqueous dispersion of claim 11, wherein a sum of the amount of the component (b) of one or more protective colloids and the optional component (el) of one or more nonionic surfactants is less than or equal to 3.4 pphm, preferably between 1-3.4 pphm, more preferably between 2-3.1 pphm.

14. The aqueous dispersion of claim 11, wherein the amount of the component (b) of one or more protective colloids is less than or equal to 2 pphm, preferably between 1.0 and 1.8 pphm, more preferably between 1.3 and 1.7 pphm.

15. The aqueous dispersion of claim 11, wherein the aqueous dispersion further comprises a component (f) of one or more thickeners; and wherein a dosage of which is less than or equal to 1 pphm, preferably less than or equal to 0.2 pphm, more preferably less than or equal to 0.5 pphm, more preferably between 0.05-0.2 pphm.

16. The aqueous dispersion of claim 11, wherein the aqueous dispersion comprises a component (d) of one or more dispersants, selected from polycarboxylates, preferably selected from ammonium polycarboxylates, sodium polycarboxylates, potassium polycarboxylates, more preferably selected from ammonium polycarboxylate.

17. The aqueous dispersion of claim 11, wherein the aqueous dispersion is used as a bonding composition, as a foaming bonding composition, as a carpet bonding composition, and/or as a carpet bonding composition having an improved water resistance effect.

18. The aqueous dispersion of claim 17, wherein the carpet is machine made carpet, a woven carpet, a tufted carpet, and/or a tufted broadloom carpet.

19. An aqueous carpet bonding composition, comprising: a component (a) of one or more ethylene-vinyl ester copolymers; a component (b) of one or more protective colloids; a component (el) of one or more nonionic surfactants; a component (d) of one or more dispersants, selected from polycarboxylates; a component (e) of solid powder; a component (g1) of one or more foaming agents; an optional component (g2) of one or more foaming aids, an optional component (f) of one or more thickeners and/or optionally an amount of water; wherein an amount of the component (b) of one or more protective colloids and the component (c1) of one or more nonionic surfactants is less than or equal to 3.4 pphm, preferably between 1-3.4 pphm, more preferably between 2-3.1 pphm; wherein the weight ratio of an amount of the component (b) of one or more protective colloids to the component (el) of one or more nonionic surfactants is between 1.01-2; wherein an amount of the component (d) of one or more dispersants is less than or equal to 1 pphm; and wherein the component (b) of one or more protective colloids is selected from polyvinyl alcohol (PVOH).

20. The aqueous carpet bonding composition of claim 19, wherein the carpet is a machine-made carpet, a tufted carpet, and/or a tufted broadloom carpet.

Description

EMBODIMENTS

[0079] PVOH 2588, a polyvinyl alcohol aqueous solution with 88 wt % hydrolysis degree. The 4 wt % aqueous solution has a viscosity of 25 mPa.Math.s measured according to DIN 53015 at 20? C. It is prepared into an aqueous solution of 10.3 wt % before use.

[0080] Non-ionic surfactant 1, an aqueous solution of Aliphatic alcohol ethoxylates, containing 30 EO units, C13 alkyl group, HLB value of 17.2.

[0081] Ammonium polycarboxylate, prepared into an aqueous solution with an active ingredient content of about 20 wt % before use. The viscosity is about 300 mPa.Math.s under the condition of pH=8-9 and 20 wt %

[0082] Thickener 1, anionic polyacrylic acid, obtained by copolymerization of acrylic acid-containing monomers, shows anionic characteristics under alkaline conditions and has a thickening effect. It is prepared into an aqueous solution with an active ingredient content of about 30 wt % before use.

[0083] tBHP, tert-butyl hydroperoxide, prepared into 10 wt?/0 aqueous solution before use. FF6, disodium glycolic acid sulfinic acid, prepared into 5 wt % aqueous solution before use (purchased from BrUggemann Chemical incorporates).

[0084] EDTA-2Na, ethylenediamine tetraacetic acid disodium salt, prepared into 8 wt % aqueous solution before use.

[0085] FeAS, ferrous ammonium sulfate, prepared into 10 wt?/0 aqueous solution before use,

[0086] Calcium carbonate, powder, the particle size is between 10-100 ?m.

[0087] Foaming agent, sodium dodecyl sulfonate.

[0088] The above substances are all commercially available.

Preparation Method

[0089] Step 1. Add deionized water, PVOH 2588 aqueous solution, non-ionic surfactant, etc. into the 5-liter reactor. Mix the ingredients well and adjust the pH of the mixture to 4 by formic acid, and then add FeAS.

[0090] Heat the reactor to about 57? C., add the first part of vinyl acetate and ethylene gas, and keep the reactor pressure below 45 bar.

[0091] Incubate at about 57? C., while adding tBHP aqueous solution and FF6M aqueous solution dropwise to initiate the reaction and continue the dropwise addition until the reaction is complete. The reaction was initiated to increase the temperature to 85? C., and the second part of vinyl acetate and ethylene gas was continuously added, and the pressure of the reactor was maintained at about 58 bar.

[0092] Step 2. After reacting for 4 hours, transfer the product to a degassing tank, add a mineral oil defoamer, and obtain an aqueous polymer dispersion after degassing for 30 minutes. The Tg of this product is between 0-5? C.; the solid content is between 54-60 wt %.

[0093] The examples and comparative examples were prepared by the above methods, and the specific components and dosages are shown in Table 1.

TABLE-US-00001 TABLE 1 Ex.0 Ex.1 Ex.2 Ex.3 C.Ex.4 C.Ex.5 VAM 82.77 82.77 82.77 82.77 82.77 82.77 Ethylene 17.23 17.23 17.23 17.23 17.23 17.23 PVOH 2588 pure material 1.42 1.42 1.42 1.42 1.2 1.0 Non-ionic surfactant 1 1.22 1.22 1.22 1.22 2.5 1.5 pure material Thickener 1 pure material 0.11 0 0 0.11 0.11 0.11 Ammonium polycarboxylate 0.04 0 0.04 0 0.04 0.04 pure material EDTA-2Na(8 wt % solution) 0.01 0.01 0.01 0.01 0.01 0.01 Formic Acid pH Adjust 0.03 0.03 0.03 0.03 0.03 0.03 (85 wt % solution) FeAS (10 wt % solution) 0.03 0.03 0.03 0.03 0.03 0.03 tBHP(10 wt % solution) 1.56 1.56 1.56 1.56 1.56 1.56 FF6 (5 wt % solution) 2.94 2.94 2.94 2.94 2.94 2.94 Solid content 58% 58% 58% 58% 58% 58% * The amount of ethylene in Table 1 refers to the amount of ethylene gas fed in each case.

[0094] According to the above method and Table 1, an aqueous dispersion composition was obtained. Mix the composition in Table 2.1 with an SFJ-400 mixer at a rate of 250 rpm to a uniform foam-containing composition and obtain the First glue. After mixing the composition of Table 2.2 by with an SFJ-400 mixer at a rate of 250 rpm, the Second glue is obtained.

TABLE-US-00002 TABLE 2.1 Recipe of the First glue Ex. 0 aqueous dispersion (58 wt % solid content ) 104 Calcium carbonate 291 Xanthan gum 1-3 Foaming agent 1.2 Water 44 Total solid content 80 wt % * The Brookfield viscosity of the First glue is between 5 000 and 7 000 mPa .Math. s.

TABLE-US-00003 TABLE 2.2 Recipe of the Second glue Ex. 0 aqueous dispersion (58 wt % solid content ) 155 Calcium carbonate 250 Xanthan gum 1-3 Water 20 Total solid content 80 wt % * The Brookfield viscosity of the Second glue is between 9 000 and 11 000 mPa .Math. s.

[0095] Sample preparation and method ST-1 for glass transition temperature measurement:

[0096] Take a certain amount of the aqueous polymer dispersion and dry at 25? C. overnight and then let stand in a vacuum oven at 40? C. for 24 hours to obtain an dried polymer product.

[0097] Take 8-15 mg of the dry product and heat from ?80? C. to 100? C. at a heating rate of 10K/min using NETZSCH F203 analyzer in a closed sample cell in protective nitrogen atmosphere, according to ISO11357-1 2014, to determine the glass transition temperature (Tg) of the dried polymer product.

[0098] Testing method ST2 Brookfield viscosity:

[0099] According to GB/T 11175-2002, using Brookfield RV/DV rotational viscometer, at 25? C., 20 rpm, use No. 4 spindle to test the viscosity of the above samples.

[0100] The room temperature conditions in the present invention refer to: a temperature of 23?2? C. and a relative humidity of 65?5%.

[0101] Laboratory bonding strength sample preparation method:

[0102] The size of the PP mesh and the tufted carpet of nylon fiber is 21 cm*30 cm.

[0103] The specific preparation steps are as follows: [0104] (1) Use a 300 ?m wet film preparation device to apply the Second glue on the glass plate with a thickness of 300 um. Spread the PP mesh on the glue surface and press the roller twice with a 2 kg roller to soak the PP mesh in the Second glue. [0105] (2) Use a spatula to evenly spread the First glue on the back surface of the carpet. The glue dosage is between 0.05-0.08 g/cm.sup.2. [0106] (3) Remove the PP mesh from the Second glue, attach the PP mesh to the back surface of the carpet, and roll the composite structure twice with a 2 kg roller to promote its adhesion. [0107] (4) Put the bonded sample into a flat heating furnace and heat it at 145? C. for 5 minutes. [0108] (5) Leave the sample at room temperature for one day. [0109] (6) Cut the sample into a 50 mm*150 mm rectangular sample. [0110] (7) Soak the sample in 80? C. water bath for 1 min, then take it out and hang it on the shelf for 15 minutes. Immediately test the 180? peel strength of the sample.

[0111] Test method ST-4 wet bonding strength:

[0112] With reference to the method shown in FIG. 1 of ISO11339-2010, the above-mentioned sample was used to measure the 180? peel strength on the XLW(G)-PC electronic tensile machine (Shandong Languang). The width of the sample is 50 mm, and the vertical stretching distance is 50 mm. The stretch value of 2 mm at both the beginning and end of the test are not considered. The stretching speed is 300 mm/m in.

TABLE-US-00004 TABLE 3 Ex. 0 Ex. 1 Ex. 2 Ex. 3 C. Ex. 4 ST-4 wet bonding strength (N) 9.1 8.4 7 6.3 5.5

[0113] The sample strips were prepared from the carpet adhesive containing Ex.0-3, and the wet bonding strength was greater than or equal to 6 N, indicating that their water resistance was good.

TABLE-US-00005 TABLE 4 Evaluation about Stability and Workability Ex. 0 Ex. 1 Ex. 2 Ex. 3 C. Ex. 5 Brookfield viscosity of the aqueous 2 000 700 700 2 000 2 000 dispersion (mPa .Math. s) Stability evaluation good middle middle good good Brookfield viscosity (mPa .Math. s) of the 6 000 5 000 3 000 24 000 10 000 mixture obtained by mixing calcium carbonate and the aqueous dispersion, wherein calcium carbonate:solid content of water dispersion = 4.8:1 Workability evaluation good good middle middle middle overview good middle middle middle middle

[0114] When the Brookfield viscosity of the aqueous dispersion is between 1200-3000 mPa.Math.s, it indicates that the stability of the aqueous dispersion is good. When the Brookfield viscosity of the mixture obtained by mixing the calcium carbonate and the aqueous dispersion is between 5000-7000 mPa.Math.s, it indicates that the aqueous dispersion has better encapsulation of calcium carbonate. A carpet adhesive with good workability can be obtained.